Most warehouse managers are aware of the dangers that come with elevated work. Whether retrieving inventory from a high rack or operating an order picker on a mezzanine, the threat of a catostrophic fall is ever-present. Accidental falls are not just a top reason for warehouse accidents; they are among the most serious, often resulting in downtime, high compensation costs, and, most importantly, lasting human impact. Yet, with the right strategies and technology, these incidents are avoidable.

The Dangers of Elevated Work

Falls from raised platforms, such as lift trucks, mezzanines, and mezzanines account for a large portion of warehouse injuries. OSHA mandates fall protection at elevations of four feet or more in general industry settings, but compliance alone does not guarantee safety. In practice, even seasoned workers can become overconfident or pressed for time, leading to lapses in tethering or harness use. The outcome can be grave: a single misstep at height can result in catastrophic harm or fatalities.

Warehouses are busy settings. Workers frequently need to reach stock stored high above the floor, using equipment like swing-reach vehicles or turret trucks. These machines are vital to efficient warehouse work, but they also introduce unique fall hazards. A momentary lapse, not attaching a lanyard or improperly securing a lanyard, can have serious consequences.

Traditional Fall Protection: Strengths and Shortcomings

Historically, warehouses have relied on a mix of protective rails, safety nets, and personal fall arrest systems to protect employees at height. Guardrails and barriers are effective on mezzanines and fixed platforms, but they cannot ensure the safety of workers on moving vehicles. Personal fall arrest systems such as lanyards and harnesses are the standard for employees on mobile lifts. Unfortunately, these systems depend on consistent human behavior. Even the best-trained worker can forget to tether in a moment of distraction, especially during high-pressure times or under production pressure.

Supervisors have long wrestled with the challenge of human error. Spot checks and routine audits are useful, but they don't ensure everyone always follows the rules, especially in large or multi-shift operations.

The Raymond iWarehouse Integrated Tether System: Compliance Made Easy

Raymond’s iWarehouse Integrated Tether System represents a leap forward in fall protection for warehouse environments where work at height is common. In contrast to traditional systems that rely solely on operator diligence, the Integrated Tether System uses advanced wireless systems to make certain that safety rules are enforced whenever an employee uses elevated equipment.

Here’s how it works: The system requires the employee to connect a self-retracting lanyard to their harness before the vehicle will function at regular speed or allow the forks to elevate. In the event that the worker isn't tethered correctly, the system immediately triggers a series of progressive warnings including sound warnings, on-screen messages, and, if unaddressed, slowing the vehicle to a crawl and shutting off lift controls. This multi-layered approach ensures that employees cannot work around required protocols, even unintentionally.

The Integrated Tether System is currently available for Raymond’s Orderpicker models (5300, 5400, 5500, 5600) and Swing-Reach trucks (9600, 9700), making it a practical solution for a wide range of warehouse operations. Besides real-time enforcement, the system supplies supervisors with compliance tracking and reporting, allowing for specific safety education and forward-thinking risk management.

Take the Next Step Toward Fall Protection

Elevated falls are a major risk in warehouse operations, but they are also among the most easily mitigated. By integrating advanced solutions like the Raymond Integrated Tether System into your safety strategy, you can go further than just meeting regulations, protecting your people, your output, and your confidence.

If you’re ready to take a proactive approach to fall protection, contact Raymond West. Our safety experts can evaluate your warehouse hazards, bring in cutting-edge solutions, and build a safer, more resilient operation—one where every worker at height comes down safely, every time.

Raymond West's Sacramento facility serves the greater Sacramento area and other parts of Northern California, including Sacramento, Elk Grove, Auburn, Placerville, Vacaville, Fairfield, Sausalito, Napa, Santa Rosa, Redding, Eureka and all surrounding areas.

Raymond West | Sacramento Material Handling Equipment Supplier

900 National Dr
Sacramento, CA 95834
(800) 675-2500